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Condition Monitoring for Predictive Maintenance to Maximize Plant Efficiency

ACTSYS Process Management Consultants Pte Ltd. Seminar on Energy Efficiency for the Process Industry

Who are we ?
Established 2001 Principal ex Shell operational and technology senior management Based in Singapore, operating regionally Specialize in Plant Performance Monitoring methodology for Power Plants, Refineries and Petrochemicals Major Clients include Tuas Power Singapore, Power Seraya Singapore, PJB Indonesia, GE Energy, Gulf Electric Thailand, EGAT, Petronas Penapisan Trengganu, Petronas Central Utilities Gebeng, ThaiOil, Malakoff, Senoko Power Singapore

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Improving Plant Energy Efficiency

Energy Index

Historical EI Operational Adjustments Retrofit Improvements Corrective Maintenance

Energy Review to identify gaps due to non optimal settings

Energy Review to identify gaps due to equipment degradation

Energy Review to identify specific energy improvement plant modifications

Further Potential Improvement

Time
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Your Cars Rising Petrol Consumption


The way you have been driving ? Tire pressure not good ? Poor Fuel Injection ? Air intake filter clogged ? Poor lubrication ? Sticky brakes ? Worn piston rings ? Choked exhaust catalytic converter ?

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Energy Intensive Equip in Process Plants


Boilers Furnaces Gas Turbines Heat Recovery Steam Generators Pumps Fans Compressors Heat exchangers Steam Turbines Condensors Power Recovery Turbines

The performance of these equipment can be adversely affected by mechanical degradation or fouling.

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Plant Equipment Degradation Examples

Boiler tube internal fouling reduces heat transfer efficiency

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Plant Equipment Degradation Examples

Boiler tube external fouling

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Plant Equipment Degradation Examples

Gas Turbine Blades fouling

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Plant Equipment Degradation Examples


Condensate Extraction Pump
E-3

Bypass Valve

Preheated Water To Deaerator

V-1

Passing Valve

Flue Gas Inlet

Feed water Preheater

Flue Gas to Stack

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Plant Equipment Degradation Examples


Boiler Feed Pump Performance
Power Consumption (kW)
1700 1650 1600 1550 1500 1450 1400 1350 1300 1250 1200 170

Pump 2 Pump 1
190 210 230 250 270

Pump 2 requiring 50-75 kW less than Pump 1

290

310

Flow (TPH)

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Plant Equipment Degradation Examples

Leaking steam not contributing to Power generation

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Plant Equipment Degradation Examples

Gouging of Steam Turbine blades causing efficiency loss

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Plant Equipment Degradation Examples

Chipped off Gas Turbine Compressor Blade

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Plant Equipment Degradation Examples


B1001 Stack Temp Vs Load Jan - Oct 2007
Boiler stack temp higher than new & clean by 20-30 degC

230 220 Stack Temp C 210 200 190 180 170 160 150 10 15

Target Stack T

20

25

30 35 BFW Flow

40

45

50

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Challenges facing the Asset Owner


Identifying plant component defects Quantifying effect of defect on overall plant efficiency Carrying out the above actions in a predictive manner and prioritizing for first opportunity corrective maintenance

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The Quantification Challenge


Lord Kelvin (1883 lecture) : I often say when we can measure what you are speaking about and express it in numbers, you know something about it; but when you cannot measure it, when you cannot express it in numbers, your knowledge is of a meager and unsatisfactory kind.

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The Quantification Challenge


Do we know the energy efficiency of the plant at a given load or throughput ? Do we know what SHOULD be the energy efficiency of the plant at the given load ? If there is a gap, do we know which plant component is causing the gap ? And do we know how much a gap is due to each plant component ?

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The Quantification Challenge


Actual and Potential Efficiency Improvement
50.800% 50.600% 50.400% 50.200% 50.000% 49.800% 49.600%
GT Compressor Fouling BFP Inefficiency LP Bypass HP Bypass Condenser Fouling IAF Pressure Drop Actual Efficiency Nov 06 0.051% 0.012% 0.300% 0.150% 0.085% 0.005% 50.300% Dec 06 0.150% 0.020% 0.320% 0.150% 0.092% 0.022% 50.100% Jan 07 0.320% 0.025% 0.288% 0.150% 0.224% 0.033% 49.800% Feb 07 0.423% 0.026% 0.310% 0.150% 0.225% 0.054% 49.700% Mar 07 0.030% 0.026% 0.310% 0.150% 0.225% 0.054% 50.040%

GT Compr Cold Wash

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Inefficient Operation of Power Plants


Average Unit Loading Thermal Efficiency Energy Consumption Annual Energy Savings MW % GJ/H GJ/Yr MWh/Yr MMBtu/Yr US$/Yr ton/Yr ton/Yr Before After 350 350 50.0 50.1 2,520 2,515 Delta Basis (0.1) 5.03 43,459 12,072 41,193 288,351 Fuel Cost is US$7/MMBtu 903 Fuel LHV = 48139 kJ/kg 2,483 Natural Gas composition C:H = 4:1

Fuel Gas Savings Cost Savings Fuel Savings CO2 Savings

Suntec City Annual Energy Cons

MWh/Yr

87,600 10 MW Power consumption

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Thermodynamic Models
Heat Balance model
Using existing measured operating conditions calculate all other unmeasured plant conditions Determine actual efficiencies of plant components

New and Clean models for plant components


For each operating point calculate the what-if benchmark performance of the plant component in a New & Clean state Comparison of the Actual vs the New & Clean performance gives a measurement of the plant component degradation

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Case Study 1 HRSG Fouling


HPBFW2 HPBFW1 GLNSTM

(Heat Recovery Steam Generator)


LPDEAR DEAER

109848
S59 SP3 S37 S38 HPBYPS V1 PI3 S40 V2 HPST LPSTOT M6 CONDSR S39 S60 M3 CWS CWR HPSTOT S26 S55 S48

BFWSPP SP5

ST Power kW
IPST LPST BFWHDR S50 S51 S52 IPBFWP HPBFWP

HPBFW

SP6 DFW IPBFW

LPBFWP S47 S54

MAKEUP PI1 HPBPSS S57 S58 S43 SP4 PI2 HPSDSH HPS IPS S35 S36 S24 S22 S29 S1 S3 RHTRS S34 HPSH2 S5 S6 S7 S8 S9 S10 S11 S12 RHDSH S25 S33 S32 S28 S13 HPECO1 S15 S27 S23 LPS S31 M5 S49 S44 S45 S46 PUMP1

GLNDCN S53 LPBFW

M4

S30

COND

S17

S18

S19

S20

S21

STACK

SP1 S2 S56 RHTR2

S4

M1 RHTR1 HPSH1 HPEVAP HPECO2 IPSHTR LPSHTR IPEVAP

SP2 S14 S16

M2 LPEVAP HPECO0 IPECO1 LPECO FWPRHT

IPECO2

GTEXH

DUCT1 FUELGS

169298 GT Power kW
TURBIN GTTURB S41

278.91 Gross Generator Output MW

GTCOMB CMPDSC GTCOMP COMPIN S42

AIR

SSGEN

INLFLT

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Case Study 1 HRSG Fouling


Gresik CCP2 HRSG2.1 Steam Prod
HP STM 1.20 1.00 Actual / N&C 0.80 0.60 0.40 0.20 0.00
11 /2 4/ 20 04 12 /1 /2 00 4 12 /8 /2 00 4 12 /1 5/ 20 04 12 /2 2/ 20 04 12 /2 9/ 20 04 1/ 5/ 20 05 1/ 12 /2 00 5
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LP STM

Case Study 1 HRSG Fouling

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Case Study 1 HRSG Fouling

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Case Study 2 FWPH Bypass Valve


Condensate Extraction Pump
E-3

Bypass Valve

Preheated Water To Deaerator

V-1

Flue Gas Inlet

Feed water Preheater

Flue Gas to Stack

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1-Jan-05 15-Jan-05 29-Jan-05 12-Feb-05 26-Feb-05 12-Mar-05 26-Mar-05 9-Apr-05 23-Apr-05 7-May-05 21-May-05 4-Jun-05 18-Jun-05 2-Jul-05 16-Jul-05 30-Jul-05 13-Aug-05 27-Aug-05 10-Sep-05 24-Sep-05 8-Oct-05 22-Oct-05 5-Nov-05 19-Nov-05 3-Dec-05 17-Dec-05 31-Dec-05

0.90

0.95

1.00

1.05

1.10

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Case Study 2 FWPH Bypass Valve

Stack (New Feedwater Preheater Temperature (Actual) /temp Vsand Clean Performance)

Stack T Feedwater Preheater T

Valve Repaired

Continuous Condition Monitoring


Plant Info System

Plant Data

Plant Data

Data Reconciliation Heat Balances Performance Models

Historical Archive

Theoretical Analysis & Interpretation


Reports

Operations & Maintenance

Decision Decision Support Support

Discussion Points

Presentation & Discussion of Results

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So what are the Benefits ?


For the Power industry for example for Singapores 6000 MW operating capacity, a 0.1% thermal efficiency loss will incur
Extra emissions 43,000 tons CO2 per year Loss of 207 GWh per year of fuel energy or at typical prices today equivalent to approx S$7-12million per year

Typically power plants operate with at least 0.5% thermal efficiency loss, some as high as 1-3% !! Imperative to ensure Power Plants operate as near as possible to New & Clean all the time

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Singapore Fuel Consumers (2005)


Power Generation 51.0% Industry 31.7% Transport 15.8%

Households 0.6% Buildings 0.9%

That the Power Generators and Process Industry have to do something is clear

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Condition Monitoring Energy Efficiency


So are the power and process industries doing this ?
Operational Adjustments Retrofit Improvements Corrective Maintenance

Energy Index

Historical EI

Energy Review to identify gaps due to non optimal settings

Energy Review to identify gaps due to equipment degradation

Energy Review to identify specific energy improvement plant modifications

Further Potential Improvement

Time
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Reasons Why there may be Gaps


Lack of inhouse thermodynamics and calculation methodology knowledge OEM guarantees do not include Energy Efficiency What is not quantified does not generate concern and is therefore not controlled Asset management and Production silos performance monitoring and energy efficiency falls in no mans land The paradox of high efficiency designs .. Auxiliary equipment power consumption often only secondary importance
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Thank you for your attention


AUXILIARY POWER (0.22%) GT SHAFT POWER (34.23%)

SHAFT POWER

ROTOR COOLING LOSS (2.09%) COMPRESSOR WORK (.% of GT Shaft Power) COMBUSTOR LOSS (0.49%)

HP TURB POWER (2.18%)

.3 5% )

CHEMICAL ENERGY (97.32%)

RADIATION LOSS (0.34%)

HP STEAM (34.39%) IP STEAM (8.6%)

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FU EL

S EN 1. SI 00 BL % E

HE AT

RA DIA T (0. ION 09 LO %) SS

LP STEAM (4.03%) STACK LOSS (8.97%)

RA DI AT (0. ION 04 LO %) SS

(1. 4

PE

AIR

LO SS

IN LE T

(0 .

08 % )

IP TURB POWER (6.68%)

D U CT

LO SS

(0

5% )

LP TURB POWER (10.87%) CONDENSER LOSS 33.53% RADIATION LOSS (0.06%)

PI

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